KR101081405B1 - A ceramic composite, a porous ceramic insulator using the ceramic composite and Making method - Google Patents
A ceramic composite, a porous ceramic insulator using the ceramic composite and Making method Download PDFInfo
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Abstract
본 발명은 샌드위치 판넬이나 방화문 중간재 등으로 널리 사용되고 있는 다공성 세라믹 단열재 및 그 조성물에 관한 것으로서, 보다 상세하게는 유리분말 44Wt% 내지 60Wt%에 플라이애쉬(Fly Ash) 8Wt% 내지 15 Wt%, 표면 처리제 인터크리트(Intercrete) 4Wt% 내지 8Wt% 및 물유리(Water Glass) 23Wt% 내지 29 Wt%를 포함하는 것을 특징으로 하는 세라믹 조성물에 관한 것이다.
상기 조성물을 이용하여 제조된 다공성 세라믹 단열재는 가볍고, 화재 시 유해 가스의 방출이 없는 친환경 소재로서, 생산 시 가공 온도를 900℃ 이하로 낮출 수 있어 생산원가가 절감되며 판상 형태로 연속적인 제조가 가능하다는 장점이 있다.The present invention relates to a porous ceramic insulator and composition thereof, which are widely used as sandwich panels, fire door intermediates, and the like, and more specifically, to 44 Wt% to 60 Wt% of glass powder, 8 Wt% to 15 Wt% of fly ash, and surface treatment agents. It relates to a ceramic composition comprising 4 to 8 Wt% of Intercrete and 23 to 29 Wt% of Water Glass.
Porous ceramic insulation prepared using the composition is a lightweight, environmentally friendly material without the emission of harmful gases in the fire, the production temperature can be lowered below 900 ℃ during production, production costs are reduced and it is possible to manufacture continuously in the form of a plate Has the advantage.
Description
본 발명은 세라믹 조성물과 이를 이용한 다공성 세라믹 단열재 및 그 제조방법에 관한 것으로, 더욱 상세하게는 유리분말 44Wt% 내지 60Wt%에 플라이애쉬(Fly Ash) 8Wt% 내지 15 Wt%, 인터크리트(Intercrete) 4Wt% 내지 8Wt% 및 물유리(Water Glass) 23Wt% 내지 29 Wt%를 포함하는 것을 특징으로 하는 세라믹 조성물과 이를 이용한 다공성 세라믹 단열재 및 그 제조방법에 관한 것이다.The present invention relates to a ceramic composition and a porous ceramic insulating material using the same, and a method of manufacturing the same. More specifically, the glass powder is 44Wt% to 60Wt% Fly Ash 8Wt% to 15 Wt%, Intercrete 4Wt It relates to a ceramic composition comprising a% to 8Wt% and 23Wt% to 29Wt% of Water Glass, a porous ceramic insulation using the same, and a method of manufacturing the same.
최근에 에너지 절약 및 온실가스 감축을 위한 많은 노력들이 진행되고 있다. 이러한 측면에서 국내 전체 에너지 소비량의 약 30%를 차지하는 건축물에 있어서도 에너지 절약을 위해서 새로운 조성물 및 이를 이용한 단열재 연구가 활발히 진행되고 있다.Recently, many efforts have been made to save energy and reduce greenhouse gases. In this regard, even in buildings that occupy about 30% of the country's total energy consumption, new compositions and thermal insulation materials using them are being actively researched for energy saving.
단열재는 열의 이동을 최소로 억제할 목적으로 사용하는 재료로써, 크게 무기계와 유기계로 나눌 수 있다. 국내는 유기 단열재가 70%를 점유하고 있으며, 무기 단열재는 화재 시 불에 잘 타지 않는 소재를 필요로 하는 산업체에서 많이 사용되고 있다.The heat insulating material is a material used for the purpose of minimizing the movement of heat, and can be roughly divided into an inorganic type and an organic type. In Korea, organic insulation occupies 70%, and inorganic insulation is widely used in industries that require materials that do not burn well in a fire.
표 1은 단열재의 종류와 각 단열재의 특성과 시공성 및 유해성 등을 정리한 것이다.Table 1 summarizes the types of insulation and the properties, workability and hazards of each insulation.
표 1를 참조하면, 대표적인 유기계인 유리면의 경우에는 유리 섬유사이의 밀봉된 공기층이 단열역할을 한다. 유리면은 불연성, 흡음성의 특징과 압축 등에 의한 유효 두께감소 및 단열성 저하 우려는 없다. 그러나 흡수성으로 인해 별도의 방습층 설치가 필요하고, 시공 시 시공자가 따가움을 호소하는 등의 문제점을 가지고 있다.Referring to Table 1, in the case of the glass surface, which is a representative organic type, the sealed air layer between the glass fibers serves as a thermal insulation. There is no fear that the glass surface will have an effective thickness reduction and heat insulation deterioration due to incombustibility, sound absorption characteristics and compression. However, due to its absorbency, it is necessary to install a separate moisture-proof layer, and there is a problem in that the builder complains of stinging.
무기계인 폴리스티렌은 단열효과가 높고 경량이며 사용이 간편하다. 그러나 자외선 등에 약하며 화재발생시 착화나 유독가스 등의 배출 위험이 높아 인체에 치명적인 위험성을 내포하고 있다.Inorganic polystyrene has high thermal insulation effect, light weight and easy to use. However, it is weak to ultraviolet rays and has a high risk of ignition or toxic gas emission in case of fire, which poses a fatal danger to the human body.
또 다른 무기계인 폴리우레탄의 경우도 시공 후 부피가 줄고 열전도율이 저하되는 단점이 있으며, 화재발생시 유독가스 등의 방출위험이 있다는 문제점을 가지고 있다.In the case of polyurethane, which is another inorganic type, there is a disadvantage that the volume decreases after construction and the thermal conductivity is lowered, and there is a problem that there is a risk of toxic gas emission in case of fire.
또한 샌드위치 판넬이나 방화문 중간재 등에 사용되고 있는 단열재들 중 유기 단열재들은 단열특성은 뛰어나나 화재 발생에 취약한 구조적인 문제점들로 인해 상품성이 없다거나 다종화하지 못하고 있고, 무기 단열재는 주로 고온의 공정 능력을 필요로 하여 공정 비용이 크다는 문제점을 가지고 있다. In addition, among the insulation materials used in sandwich panels and fire door intermediate materials, organic insulation materials have excellent insulation properties but are not commercialized or diversified due to structural problems vulnerable to fire, and inorganic insulation materials require high temperature processing capability. As a result, the process cost is high.
한편, 세라믹 조성물을 이용한 세라믹 단열재 경우에 있어서는 그 제조방법으로 겔 캐스팅(Gel Casting)과 이중 에멀젼(Emulsion)을 동시에 적용한 발포법(Foaming)과 플라이애쉬(Fly Ash), 점토 등을 주원료로 하고 발포제로 탄산칼슘(CaCO3) 및 카본 등을 사용하는 발포법 등이 있다. 이에 의해 제조된 다공성 단열재는 원료의 조성, 입도 등의 물성, 발포제의 종류 및 함량에 따라 기공의 구조가 달라진다. On the other hand, in the case of ceramic insulators using ceramic compositions, foaming method, fly ash, clay, etc., which are simultaneously applied with gel casting and double emulsion, are mainly used as the manufacturing method. And foaming methods using calcium carbonate (CaCO 3 ), carbon and the like. Porous heat insulating material produced by this is the structure of the pores according to the composition of the raw material, physical properties such as particle size, type and content of the blowing agent.
기타 폐유리를 주원료로 하고 발포제로 삼산화철(Fe2O3)을 사용하면서 소성을 반복하여 개기공(Open Pore)을 형성시키는 2중소성법 있다. 이에 의한 다공성 단열재는 크기가 작은 기공을 형성한다.In addition, there is a double firing method in which waste glass is used as a main raw material and iron trioxide (Fe 2 O 3 ) is used as a blowing agent, and firing is repeated to form open pores. The porous insulation thereby forms small pores.
그러나 이러한 방법들은 특정 재료의 첨가를 많이 하거나 가압 등을 통한 공정 변경 등을 제외하고는 보통 1000℃ 이상의 온도를 필요로 하는 문제점을 가지고 있다.However, these methods have a problem that usually requires a temperature of more than 1000 ℃ except for the addition of a specific material or a process change through pressure and the like.
본 발명이 해결하려는 과제는 세라믹 고유의 기능을 보전하면서 세라믹 조성물의 내부에 폐기공을 도입함으로써 경량성, 단열성 및 난연성 등의 특성이 향상되고, 인체에 무해한 친환경성을 가진 세라믹 조성물 및 이를 이용한 다공성 세라믹 단열재를 제공하는 것이다.The problem to be solved by the present invention is to improve the characteristics such as light weight, heat insulation and flame retardancy by introducing a waste hole in the ceramic composition while maintaining the intrinsic function of the ceramic, and a ceramic composition having an eco-friendly harmless to the human body and porous using the same It is to provide a ceramic insulation.
본 발명이 해결하고자 하는 또 다른 과제는 저온의 열처리 과정을 가짐으로써, 생산원가를 낮추고 대량생산이 가능하게끔 하는 다공성 세라믹 단열재의 제조방법을 제공하는 것이다.Another problem to be solved by the present invention is to provide a method of manufacturing a porous ceramic insulation material having a low temperature heat treatment process, thereby lowering the production cost and enabling mass production.
상기 기술적 과제를 이루기 위한 본 발명에 따른 세라믹 조성물은 유리분말(혹은 폐유리 분말) 44Wt% 내지 60Wt%, 플라이애쉬(Fly Ash) 8Wt% 내지15 Wt%, 표면 처리제인 인터크리트(Intercrete) 4Wt% 내지 8Wt%, 및 물유리(Water Glass) 23Wt% 내지 29 Wt%를 포함하는 것을 특징으로 한다.Ceramic composition according to the present invention for achieving the above technical problem is 44Wt% to 60Wt% of glass powder (or waste glass powder), 8Wt% to 15Wt% of fly ash, Intercrete 4Wt% surface treatment agent To 8 Wt%, and water glass (Water Glass) 23 Wt% to 29 Wt%.
상기 기술적 과제를 이루기 위한 본 발명에 따른 다공성 세라믹 단열재는 상기 조성물로 이루어지며, 비중 0.3 내지 0.5g/cm3, 굴곡 강도 40 Kgf/cm2 이하, 열전도율 0.1 내지 0.14 W/mK의 물성, 및 난연 1급의 난연성을 가지는 것을 특징으로 한다.Porous ceramic insulation according to the present invention for achieving the above technical problem is made of the composition, specific gravity 0.3 to 0.5g / cm 3 , flexural strength of 40 Kgf / cm 2 or less, thermal conductivity of 0.1 to 0.14 W / mK, and flame retardant It is characterized by having a first-class flame retardancy.
상기 또 다른 기술적 과제를 이루기 위한 본 발명에 따른 다공성 세라믹 단열재의 제조방법은 상기 조성물들을 혼합하는 단계, 혼합된 조성물을 건조 및 분쇄하는 단계, 건조 및 분쇄된 혼합 분말을 열처리로에 넣어 800℃~900℃에서 20분 내지 3시간 소성 및 발포하는 단계, 이와 같이 열처리된 성형체를 자연 냉각하는 단계, 및 냉각된 성형체를 용도에 맞게 절단 가공하는 단계를 포함하는 것을 특징으로 한다.Method for producing a porous ceramic insulation according to the present invention for achieving the above another technical problem is a step of mixing the compositions, drying and pulverizing the mixed composition, put the dried and pulverized mixed powder in a heat treatment furnace 800 ℃ ~ Firing and foaming at 900 ° C. for 20 minutes to 3 hours, naturally cooling the heat-treated molded body, and cutting the cooled molded body according to a use.
본 발명에 따른 세라믹 조성물 및 이를 이용한 다공성 세라믹 단열재는 비중이 낮고 이로 인해 열전도율이 낮으며 난연성이 우수한 장점이 있다. 또한 화재 발생 시 유해 가스의 방출이 없는 친환경 소재로서, 생산 시 800℃ 내지 900℃ 이하의 저온 공정이 가능하다. 이로 인해 생산원가가 절감되고 판상 형태의 연속적인 제조가 가능하다는 장점이 있다.The ceramic composition and the porous ceramic heat insulating material using the same according to the present invention have a low specific gravity, and thus have low thermal conductivity and excellent flame retardancy. In addition, it is an environmentally friendly material that does not emit harmful gases in the event of a fire, and low temperature processes of 800 ° C. to 900 ° C. or lower are possible in production. This reduces the production cost and has the advantage that the continuous manufacturing in the form of a plate.
본 발명에서 제시한 방법에 의해 제조된 다공성 세라믹 단열재는 비중 0.3 내지 0.5g/cm3, 굴곡 강도 40 Kgf/cm2이하, 열전도율 0.1 내지 0.14 W/mK의 물성과 난연 1급의 특성이 있다.Porous ceramic insulation prepared by the method proposed in the present invention has a specific gravity of 0.3 to 0.5g / cm 3 , flexural strength of 40 Kgf / cm 2 or less, thermal conductivity of 0.1 to 0.14 W / mK and properties of flame retardant primary.
도 1은 각 원료의 조성 비율을 달리하여 제조된 세라믹 단열재 사진이다.
도 2a는 본 발명의 일실시예에 따른 세라믹 조성물 내 유리분말의 성분분석 결과이다.
도 2b는 본 발명의 일실시예에 따른 세라믹 조성물 내 플라이애쉬(Fly Ash)의 성분분석 결과이다.
도 2c는 본 발명의 일실시예에 따른 세라믹 조성물 내 인터크리트(Intercrete)의 성분분석 결과이다.
도 3은 본 발명에 따라 조성물을 이용한 다공성 세라믹 단열재의 제조 공정도이다.
도 4는 본 발명의 일실시예에 따라 제조된 판상 형태의 단열재 사진이다.1 is a photograph of a ceramic insulation prepared by varying the composition ratio of each raw material.
Figure 2a is a result of the component analysis of the glass powder in the ceramic composition according to an embodiment of the present invention.
Figure 2b is a result of the component analysis of the fly ash (Fly Ash) in the ceramic composition according to an embodiment of the present invention.
2c is a result of component analysis of intercrete in a ceramic composition according to an embodiment of the present invention.
Figure 3 is a manufacturing process of the porous ceramic insulation using the composition according to the present invention.
Figure 4 is a photograph of the heat insulating material of the plate shape manufactured according to an embodiment of the present invention.
이하, 첨부된 도면을 참조하여 본 발명을 보다 상세히 설명하도록 한다.Hereinafter, with reference to the accompanying drawings to describe the present invention in more detail.
도 1은 각 원료의 조성 비율을 달리하여 제조된 세라믹 단열재들의 겉보기 확대사진, 현미경 사진, 수분 흡수정도, 열전도도 및 비중을 나타낸 것이다. Figure 1 shows the apparent magnification, micrographs, moisture absorption, thermal conductivity and specific gravity of the ceramic insulation prepared by varying the composition ratio of each raw material.
실시예 1은 본 발명이 제안한 조성 범위 내에서 제조된 세라믹 단열재이다. 그 외 실시예 2는 인터크리트(Intercrete) 성분을 첨가하지 않았으며, 실시예 3은 플라이애쉬(Fly ash) 성분을 25 Wt%로 하여 본 발명의 제안 범위를 넘어서 실시하였다. 한편 실시예4에서는 인터크리트(Intercrete)를 첨가하지 않음과 동시에 플라이애쉬(Fly ash) 성분을 29 Wt%로 하여 실시하였다.Example 1 is a ceramic insulating material manufactured within the composition range proposed by the present invention. The other Example 2 did not add the Intercrete component, Example 3 was carried out beyond the proposed range of the present invention with a fly ash component of 25 Wt%. On the other hand, Example 4 was carried out with 29 Wt% of fly ash (Fly ash) while not adding intercrete.
실시 예 1, 2, 3에서는 세라믹 소재의 강도를 증진시키기 위하여 게르마늄(Ge) 8 Wt%를 첨가하여 실시하였다.In Examples 1, 2 and 3, 8 Wt% of germanium (Ge) was added to increase the strength of the ceramic material.
도 1을 참고하면, 본 발명이 제안한 조성 범위 내에서 제조된 세라믹 단열재만이 수분 흡수율이 상대적으로 적고, 열전도도가 0.181 W/mK로 낮으며, 비중 또한 0.533g/cm3 으로 낮아 가벼우면서 단열 효과도 우수함을 알 수 있다.Referring to FIG. 1, only the ceramic heat insulating material manufactured within the composition range proposed by the present invention has a relatively low water absorption, low thermal conductivity of 0.181 W / mK, and low specific gravity of 0.533 g / cm 3 . It can be seen that the effect is also excellent.
도 1의 실시예1처럼 적절한 발포 및 폐기공 크기를 형성하려면 유리분말, 플라이애쉬(Fly Ash), 인터크리트(Intercrete) 및 물유리(Water Glass)가 일정한 조성 범위에 있어야만 본 발명의 목적에 적합한 생산원가가 낮고 경량성, 단열성 및 난연성 등의 특성을 가진 다공성 세라믹 단열재를 제조할 수 있게 되는데, 그 구체적인 이유에 대해 설명하기로 한다.In order to form an appropriate foaming and disposal hole size as in Example 1 of Figure 1, the glass powder, fly ash, intercrete and water glass must be in a certain composition range for production suitable for the purpose of the present invention. It is possible to manufacture a porous ceramic insulation having low cost, light weight, heat insulation and flame retardant properties, the specific reason will be described.
상기 유리 분말은 일반 유리 분말뿐만 아니라 폐유리 분말의 적용도 가능하다. 유리 분말은 연화점을 낮춰 비교적 낮은 온도에서도 발포가 가능하도록 돕는 기능과 유리화에 의한 강도 개선 및 유지를 목적으로 한다. The glass powder may be applied to waste glass powder as well as ordinary glass powder. The glass powder aims at lowering the softening point to enable foaming even at relatively low temperatures, and for improving and maintaining strength by vitrification.
본 발명에 사용된 유리분말은 전체 조성물의 44Wt% 내지 60Wt%인 것이 가장 바람직하다. 이는 44Wt% 이하가 되면 기공의 크기가 작아지면서 밀도가 증가하는 현상이 나타나며, 60 Wt% 이상이 되면 표면이 유리화되고 과대 발포 현상이 나타나 바람직하지 않기 때문이다.The glass powder used in the present invention is most preferably 44Wt% to 60Wt% of the total composition. This is because when the size is less than 44Wt%, the size of the pores decreases and the density increases, and when more than 60Wt%, the surface is vitrified and the excessive foaming phenomenon is not preferable.
상기 플라이애쉬(Fly Ash)는 석탄 연소 후 발생되는 부산물로서 집진기에서 포집되는 미세한 분말 형태이다. 포졸란성(Pozzolan)의 대표 물질로써 석회와 결합하여 물을 만나면 상온에서 시멘트 성질을 가지는 화합물을 생성한다. 현재 플라이애쉬(Fly Ash)는 시멘트 대체재로 우수한 특성을 지니고 있다. The fly ash (Fly Ash) is a fine powder form collected by the dust collector as a by-product generated after coal combustion. Representative material of Pozzolan (Pozzolan) when combined with lime to meet the water to produce a compound having a cement property at room temperature. Fly Ash is currently a cement replacement material.
본 발명에 사용된 플라이애쉬(Fly Ash)는 전체 조성물의 8Wt% 내지 15 Wt%인 것이 바람직하다. 8Wt%이하가 되면 과대 발포와 함께 강도가 떨어지며, 15Wt%이상이 되면 발포 현상이 극도로 억제되면서 기공이 작아지고 밀도가 증가되어 바람직하지 않기 때문이다.The fly ash used in the present invention is preferably 8 Wt% to 15 Wt% of the total composition. If it is less than 8Wt%, the strength falls with excessive foaming, and if it is more than 15Wt%, the foaming phenomenon is extremely suppressed, and the pores are reduced and the density is increased, which is undesirable.
상기 인터크리트(Intercrete)는 시멘트 사용 시 급결제로 주로 사용되고 있기도 하다. 그 성분이 주재료인 유리 분말과 비슷하나, 통상의 유리 분말의 성분 중 산화칼슘(CaO) 성분이 조금 많은 재료로써, 발포된 성형체의 상부 표면을 거칠지 않고 매끄럽게 해 주기 위해 사용된다.Intercrete is also mainly used as a fastener when using cement. Although the component is similar to the glass powder which is a main material, it is a material with a little calcium oxide (CaO) component among the components of a normal glass powder, and is used in order to make the upper surface of a foamed molded object smooth and smooth.
발포 정도에 따른 상부표면의 평활도를 개선시켜 부피가 큰 판상 형태의 성형체를 제조할 목적인 경우, 절단 및 가공단계에서 버려지는 부분을 절감시켜 주는 효과가 있다. 본 발명에서는 4Wt% 내지 8 Wt%의 혼합비가 가장 적당하다.When the purpose of manufacturing a bulky plate-shaped molded body by improving the smoothness of the upper surface according to the degree of foaming, there is an effect of reducing the portion discarded in the cutting and processing steps. In the present invention, a mixing ratio of 4 Wt% to 8 Wt% is most suitable.
4Wt%이하에서는 발포력에 의해 시료의 상부 표면층이 둥글게 부풀려 올라 상기에서 언급한 바와 같이 큰 판상 형태의 성형체일 경우 절단 시 버려지는 부분이 증가하여 생산원가의 상승 원인이 될 수 있고, 8 Wt% 이상은 성형체의 평탄도 측면에서는 별 차이 없으나 추가량에 의한 생산비 증가가 예상되어 바람직하지 못하다.Below 4 Wt%, the upper surface layer of the sample is swollen by the foaming force, and as mentioned above, in the case of a large plate-shaped molded part, the discarded portion may increase due to the increase in production cost, and 8 Wt% The above is not a difference in terms of flatness of the molded body, but it is not preferable because the production cost is increased by the additional amount.
상기 물유리(Water Glass)는 수용성 규산염 중 가장 널리 사용되고 있는 무기 화합물이다. 물에 대한 용해성 때문에 물유리(Water Glass)로 불리어 지고 있다. 이는 알카리 금속이 이산화규소(SiO2)와 다양한 몰비로 결합한 화합물로써 규산나트륨(Sodium Silicate), 규산 칼륨(Potassium Silicate), 리튬 실리케이트(Lithium Silicate) 등이 있으며 자체적으로 10% 내지 30% 정도의 물을 포함하고 있다. 물유리(Water Glass)는 순도 높은 모래를 탄산나트륨(Na2CO3) 또는 탄산칼륨(K2CO3)와 함께 1100~1200℃에서 용융시켜 만들어 진다.The water glass is the most widely used inorganic compound among water-soluble silicates. Due to its solubility in water, it is called water glass. It is a compound in which alkali metal is combined with silicon dioxide (SiO 2 ) in various molar ratios, such as sodium silicate, potassium silicate, lithium silicate, and water of about 10% to 30% by itself. It includes. Water Glass is made by melting high-purity sand with sodium carbonate (Na 2 CO 3 ) or potassium carbonate (K 2 CO 3 ) at 1100 ~ 1200 ℃.
본 발명에 사용된 물유리(Water Glass)는 전체 조성물의 23Wt% 내지 29 Wt%인 것이 바람직하다. 23 Wt%이하에서는 발포력이 떨어져 무게가 무거워지며, 29 Wt%이상에서는 과대 발포에 의한 표면 유리화가 진행되어 바람직하지 않기 때문이다.The water glass used in the present invention is preferably 23 Wt% to 29 Wt% of the total composition. This is because the foaming force is lowered at 23 Wt% or less and the weight becomes heavy. At 29 Wt% or more, surface vitrification due to excessive foaming proceeds, which is undesirable.
도 2a, 도 2b, 및 도2c는 본 발명의 일실시례에 따른 세라믹 조성물의 유리분말, 플라이애쉬(Fly ash) 및 인터크리트(Intercrete) 각각의 성분분석 결과를 나타낸 도면이다.2A, 2B, and 2C are diagrams showing the results of component analysis of the glass powder, fly ash, and intercrete of the ceramic composition according to the embodiment of the present invention.
도 2a에 도시된 바와 같이, 유리분말은 이산화규소(SiO2)가 62.50Wt% 내지 72.50 Wt%, 산화칼슘(CaO)이 9.75Wt% 내지 22.30 Wt%, 및 산화나트륨(Na2O)이 8.00Wt% 내지 13.70Wt%의 성분을 함유하고 있으며, 기타 산화마그네슘(MgO), 알루미나(Al2O3), 산화칼륨(K2O) 등을 3.8Wt% 내지 7.2Wt% 포함하고 있다.As shown in FIG. 2A, the glass powder is 62.50 Wt% to 72.50 Wt% of silicon dioxide (SiO 2 ), 9.75 Wt% to 22.30 Wt% of calcium oxide (CaO), and 8.00 of sodium oxide (Na 2 O). Wt% to 13.70Wt%, and other magnesium oxide (MgO), alumina (Al 2 O 3 ), potassium oxide (K 2 O) and the like 3.8Wt% to 7.2Wt%.
또한 도 2b에 도시된 바와 같이, 플라이애쉬(Fly ash)는 SiO2 54.5Wt%, 알루미나(Al2O3) 21.1Wt% 및 삼산화철(Fe2O3) 3.49Wt%로 세 성분의 합이 70Wt% 이상 함유되어 있으며 기타 산화칼슘(CaO), 삼산화황(SO3), 오산화인(P2O5), 이산화티타늄(TiO2), 산화나트륨(Na2O), 산화스트론튬(SrO), 산화바륨(BaO) 등의 성분을 포함하고 있다.In addition, as shown in Figure 2b, fly ash (Fly ash) is 54.5Wt% of SiO 2, 21.1Wt% of alumina (Al 2 O 3 ) and 3.49Wt% of iron trioxide (Fe 2 O 3 ) is the sum of the three components It contains more than 70Wt% and other calcium oxide (CaO), sulfur trioxide (SO 3 ), phosphorus pentoxide (P 2 O 5 ), titanium dioxide (TiO 2 ), sodium oxide (Na 2 O), strontium oxide (SrO), oxidation It contains components such as barium (BaO).
또한 도 2c에 도시된 바와 같이, 인터크리트(Intercrete)는 이산화규소(SiO2) 62.40Wt%, 산화칼슘(CaO) 22.5Wt% 및 산화나트륨(Na2O) 7.70Wt%의 성분을 포함하고 있다.Also, as shown in FIG. 2C, Intercrete contains 62.40 Wt% of silicon dioxide (SiO 2 ), 22.5 Wt% of calcium oxide (CaO), and 7.70 Wt% of sodium oxide (Na 2 O). .
도 3은 본 발명에 따른 조성물을 이용한 다공성 세라믹 단열재를 제조하는 전체 공정도이며, 도 4는 본 발명의 일실시예에 따라 제작된 판상 형태의 단열재 사진이다.3 is an overall process chart for manufacturing a porous ceramic insulation using the composition according to the invention, Figure 4 is a photograph of the heat insulating material of the plate-shaped form produced according to an embodiment of the present invention.
도 3을 참조하면, 본 발명에 따른 다공성 세라믹 단열재 제조방법은 혼합단계(S310), 건조 및 분쇄단계(S320), 열처리단계(S330), 냉각단계(S340) 및 절단 및 가공단계(S350)를 구비한다. Referring to Figure 3, the porous ceramic insulating material manufacturing method according to the present invention mixing step (S310), drying and grinding step (S320), heat treatment step (S330), cooling step (S340) and cutting and processing step (S350) Equipped.
상기 혼합단계(S310)에서는 유리분말(혹은 폐유리 분말) 44Wt% 내지 60Wt%에 플라이애쉬(Fly Ash) 8Wt% 내지 15 Wt%와 표면 처리제인 인터크리트(Intercrete) 4Wt% 내지 8Wt% 및 물유리(Water Glass) 23Wt% 내지 29 Wt%를 혼합한다.In the mixing step (S310) the glass powder (or waste glass powder) 44Wt% to 60Wt% fly ash (Fly Ash) 8Wt% to 15 Wt% and Intercrete 4Wt% to 8Wt% and the water glass ( Water Glass) 23 Wt% to 29 Wt% is mixed.
상기 건조 및 분쇄단계(S320)에서는 이와 같이 혼합된 조성물을 건조한 후 분쇄한다.In the drying and grinding step (S320), the mixed composition is dried and then ground.
상기 열처리단계(S330)에서는 상기 분쇄된 조성물을 열처리하여 소성 및 발포한다. 이때 열처리 온도를 800℃ 내지 900℃의 저온으로 하여 소성 및 발포 할 수 있으므로 제조 단가의 절감을 가져올 수 있다.In the heat treatment step (S330), the pulverized composition is heat-treated and fired. At this time, since the heat treatment temperature can be fired and foamed at a low temperature of 800 ° C to 900 ° C, manufacturing cost can be reduced.
상기 냉각단계(S340)에서는 열처리된 성형체를 냉각한다. 이 때 냉각은 자연 냉각을 하는 것이 바람직하나 대량 생산 시에는 공정 회전률 등을 고려하여 일정 온도 이하에서는 강제 공냉식을 적용하여 그 시간을 단축시킬 수도 있다.In the cooling step (S340) to cool the heat-treated molded body. At this time, the cooling is preferably natural cooling, but in the case of mass production, the time may be shortened by applying forced air cooling below a certain temperature in consideration of the process rotation rate.
상기 절단 및 가공단계(S350)에서는 용도에 맞게 성형체를 절단 및 가공한다. 특히 도 4에서 보이는 사진과 같이, 큰 판상 형태(950 x 650mm)의 연속적인 제조가 가능하여 이를 중간재로 이용하는 제품의 적용에 유용하다.In the cutting and processing step (S350) to cut and process the molded body according to the application. In particular, as shown in the photograph shown in Figure 4, it is possible to continuously manufacture a large plate-like form (950 x 650mm) is useful for the application of the product using this as an intermediate material.
지금까지 본 발명과 비슷한 형태의 연구와 개발이 학계를 비롯해 여러 연구기관에서 진행되어 왔지만, 그 수준이 연구를 진행하는 환경 하에 있어 부피가 작은 이른바 실험실 수준의 시료 개발에 거친 것이 대부분이었다. 또한 부피가 큰 형태의 성형체를 개발한다 하더라도 기공 크기의 균일도 측면에서 낮은 수준에 머물러 왔는데, 이의 원인으로 여러 가지가 있을 수 있겠지만, 특히 원료로 사용되는 각 재료의 특성 균일도가 그 원인 중 하나라고 추정되고 있다.Until now, research and development in a form similar to the present invention has been conducted in various research institutes, including academia, but most of them have undergone the development of so-called small lab-level samples under the environment in which the research is conducted. In addition, even in the case of the development of bulky shaped articles, the uniformity of the pore size has remained low. There may be various reasons for this, but in particular, the characteristic uniformity of each material used as a raw material is considered one of the causes It is becoming.
예를 들면 광물의 경우 어느 지역의 원료인지에 대한 철저한 이력 관리를 하지 않으면 같은 이름의 광물일지라도 이를 이용한 제품의 특성 균일도를 장담할 수 없게 된다. For example, if the minerals are not closely tracked as to which region's raw materials, even minerals of the same name cannot guarantee the product's uniformity of properties.
본 발명에서는 각 재료의 철저한 이력 관리와 함께 각 시료의 세부적인 특성을 관리하는 방법과 각 원료의 조성비 및 열처리 온도 등에 대해 많은 시행착오를 겪으며, 가장 공정 마진이 있는 조건의 추출에 지속적인 노력을 시행한 결과, 연속적인 제조공정을 통해 부피가 큰 성형체를 제조할 수 있게 되었으며 이를 통해 본격적인 대량생산의 기본 토대를 구출할 수 있게 되었다. In the present invention, a thorough history management of each material, a method of managing the detailed characteristics of each sample, and a lot of trial and error about the composition ratio and heat treatment temperature of each raw material, and the continuous efforts to extract the conditions with the most process margin As a result, it is possible to manufacture bulky molded articles through a continuous manufacturing process, which can rescue the basic foundation for full-scale mass production.
살펴본 바와 같이 본 발명에 따른 다공성 세라믹 단열재의 제조방법에 의하면, 적절한 폐기공 조직이 생성되어 경량성, 단열성 및 난연성 등의 특성이 우수한 다공성 세라믹 단열재를 제조할 수 있으며, 연속공정을 통해 큰 판상형태로 제조할 수 있다는 장점이 있다. As described above, according to the method of manufacturing the porous ceramic insulation according to the present invention, an appropriate closed hole structure is generated to produce a porous ceramic insulation having excellent properties such as light weight, heat insulation, and flame retardancy, and a large plate shape through a continuous process. There is an advantage that can be manufactured.
이상에서 본 발명에 대한 기술사상을 첨부 도면과 함께 서술하였지만 이는본 발명의 바람직한 실시 예를 예시적으로 설명한 것이지 본 발명을 한정하는 것은 아니다. 또한 본 발명이 속하는 기술 분야에서 통상의 지식을 가진 자라면 누구나 본 발명의 기술적 사상의 범주를 이탈하지 않는 범위 내에서 다양한 변형 및 모방이 가능함은 명백한 사실이다. The technical spirit of the present invention has been described above with reference to the accompanying drawings, but this is by way of example only and not by way of limitation to the present invention. In addition, it is obvious that any person skilled in the art to which the present invention pertains can make various modifications and imitations without departing from the scope of the technical idea of the present invention.
Claims (9)
플라이애쉬(Fly Ash) 8.00Wt% 내지 15.00 Wt%;
인터크리트(Intercrete) 4.00Wt% 내지 8.00 Wt%; 및
물유리(Water Glass) 23.00Wt% 내지 29.00 Wt%를 포함하는 것을 특징으로 하는 세라믹 조성물.Glass powder 44.00 Wt% to 60.00 Wt%;
Fly Ash 8.00 Wt% to 15.00 Wt%;
Intercrete 4.00 Wt% to 8.00 Wt%; And
Water Glass (Water Glass) Ceramic composition, comprising 23.00 Wt% to 29.00 Wt%.
62.50Wt% 내지 72.50 Wt%의 이산화규소(SiO2);
9.75Wt% 내지 22.30 Wt%의 산화칼슘(CaO); 및
8.00Wt% 내지 13.70 Wt%의 산화나트륨(Na2O)를 포함하는 것을 특징으로 하는 세라믹 조성물. The method of claim 1, wherein the glass powder
62.50 Wt% to 72.50 Wt% silicon dioxide (SiO 2 );
9.75 Wt% to 22.30 Wt% calcium oxide (CaO); And
Ceramic composition, characterized in that it comprises from 8.00 Wt% to 13.70 Wt% sodium oxide (Na 2 O).
54.5Wt%의 이산화규소(SiO2);
21.1Wt%의 알루미나(Al2O3); 및
3.49Wt%의 삼산화철(Fe2O3)을 포함하는 것을 특징으로 하는 세라믹 조성물. The method of claim 2, wherein the fly ash (Fly Ash)
54.5 Wt% silicon dioxide (SiO 2 );
21.1 Wt% alumina (Al 2 O 3) ; And
3.49 Wt% of iron trioxide (Fe 2 O 3 ) comprising a ceramic composition.
62.40Wt%의 이산화규소(SiO2);
22.50Wt%의 산화칼슘(CaO); 및
7.70Wt%의 산화나트륨(Na2O)를 포함하는 것을 특징으로 하는 세라믹 조성물.The method of claim 3, wherein the intercrete (Intercrete) is
62.40 Wt% silicon dioxide (SiO 2 );
22.50 Wt% calcium oxide (CaO); And
Ceramic composition, characterized in that it comprises 7.70Wt% sodium oxide (Na 2 O).
폐유리 분말인 것을 특징으로 하는 세라믹 조성물.The method of claim 1, wherein the glass powder
Ceramic composition, characterized in that the waste glass powder.
상기 조성물의 혼합단계;
혼합된 분말의 건조 및 분쇄단계;
건조 및 분쇄된 분말의 소성 및 발포를 위한 열처리단계;
열처리된 성형체의 냉각단계; 및
냉각된 성형체의 절단 및 가공단계를 포함하는 것을 특징으로 하는 다공성 세라믹 단열재의 제조 방법.In the method of manufacturing a porous ceramic heat insulator made of the composition according to any one of claims 1 to 5,
Mixing the composition;
Drying and pulverizing the mixed powder;
A heat treatment step for firing and foaming the dried and pulverized powder;
A cooling step of the heat-treated molded body; And
Method for producing a porous ceramic insulation, comprising the step of cutting and processing the cooled molded body.
800℃ 내지 900℃에서 20분 내지 3시간 동안 이루어지는 것을 특징으로 하는 다공성 세라믹 단열재의 제조 방법.The method of claim 7, wherein the heat treatment step
Method for producing a porous ceramic insulation, characterized in that made for 20 minutes to 3 hours at 800 ℃ to 900 ℃.
상기 유리분말, 상기 플라이애쉬, 상기 인터크리트 및 상기 물유리 외에 게르마늄(Ge)을 첨가하여 혼합하는 것을 특징으로 하는 다공성 세라믹 단열재의 제조 방법.The method of claim 7, wherein in the mixing of the composition
The method of manufacturing a porous ceramic insulation, characterized in that by adding and mixing germanium (Ge) in addition to the glass powder, the fly ash, the intercrete and the water glass.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR1020100019640A KR101081405B1 (en) | 2010-03-05 | 2010-03-05 | A ceramic composite, a porous ceramic insulator using the ceramic composite and Making method |
| US13/582,973 US8846557B2 (en) | 2010-03-05 | 2011-02-17 | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
| PCT/KR2011/001057 WO2011108817A2 (en) | 2010-03-05 | 2011-02-17 | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
| EP11750874.7A EP2543651A4 (en) | 2010-03-05 | 2011-02-17 | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
| CN201180012619.9A CN102791655B (en) | 2010-03-05 | 2011-02-17 | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
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| KR1020100019640A KR101081405B1 (en) | 2010-03-05 | 2010-03-05 | A ceramic composite, a porous ceramic insulator using the ceramic composite and Making method |
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| US (1) | US8846557B2 (en) |
| EP (1) | EP2543651A4 (en) |
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| KR101165565B1 (en) | 2012-03-08 | 2012-07-16 | 주식회사 케이피 | A environmental-friendly composite pannel containing nonflammable interior material for vessel furniture |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2012044057A2 (en) * | 2010-10-01 | 2012-04-05 | 주식회사 지메텍 | Water-permeable ceramic block composition using bottom ash, water-permeable porous ceramic block using same, and method for preparing same |
| KR101413908B1 (en) * | 2014-02-17 | 2014-06-30 | 에이티이 주식회사 | Dry type desulfuriation apparatus |
| CN106832444A (en) * | 2016-12-16 | 2017-06-13 | 吴中区穹窿山天仲高分子材料技术研究所 | A kind of modified abrasion resistant oil resistant flame retardant rubber |
| KR101885583B1 (en) | 2017-03-30 | 2018-09-06 | 주식회사 벽산 | Binder composition, inorganic fiber insulator for refractory structure comprising the same and method for preparing inorganic fiber insulator |
| CN115448706B (en) * | 2021-06-09 | 2023-08-15 | 中国科学院过程工程研究所 | Diatomite-based heating element and preparation method and application thereof |
| KR102708518B1 (en) * | 2022-06-22 | 2024-09-20 | 와이이케이글래스 주식회사 | Impact resistance improvement method of a plurality of diced and sintered glass |
| KR102618661B1 (en) * | 2023-02-28 | 2023-12-28 | 한국세라믹기술원 | Lightweight porous ceramic buoy block and its manufacturing method |
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| JP2001328859A (en) | 2000-05-18 | 2001-11-27 | Tadashi Fukiya | Indoor ceramic construction material having respirability |
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| US4430108A (en) * | 1981-10-14 | 1984-02-07 | Pedro Buarque De Macedo | Method for making foam glass from diatomaceous earth and fly ash |
| KR910000575A (en) | 1989-06-20 | 1991-01-29 | 안영모 | Manufacturing method of ceramic filter for water purification |
| US5588977A (en) * | 1993-11-02 | 1996-12-31 | East West Trade Group, Inc. | Method of producing glass materials from ash-slag waste |
| KR0130603B1 (en) | 1994-09-23 | 1998-04-10 | 최철성 | Pavings made of single units |
| KR20020011267A (en) | 2000-08-01 | 2002-02-08 | 이태환 | Bacteria living material and its manufacture method |
| CN1167640C (en) * | 2002-07-15 | 2004-09-22 | 南京大学 | Foamed glass ceramic material for wall and its production process |
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| CN101597139B (en) * | 2009-07-03 | 2010-12-29 | 陕西科技大学 | Method for preparing foamed glass insulation board by coal ash |
| WO2012044057A2 (en) * | 2010-10-01 | 2012-04-05 | 주식회사 지메텍 | Water-permeable ceramic block composition using bottom ash, water-permeable porous ceramic block using same, and method for preparing same |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2001328859A (en) | 2000-05-18 | 2001-11-27 | Tadashi Fukiya | Indoor ceramic construction material having respirability |
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| KR101165565B1 (en) | 2012-03-08 | 2012-07-16 | 주식회사 케이피 | A environmental-friendly composite pannel containing nonflammable interior material for vessel furniture |
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| US20130029129A1 (en) | 2013-01-31 |
| KR20110100689A (en) | 2011-09-15 |
| WO2011108817A2 (en) | 2011-09-09 |
| EP2543651A4 (en) | 2013-07-31 |
| CN102791655B (en) | 2014-05-28 |
| EP2543651A2 (en) | 2013-01-09 |
| US8846557B2 (en) | 2014-09-30 |
| CN102791655A (en) | 2012-11-21 |
| WO2011108817A3 (en) | 2012-01-05 |
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